Hosiery garments with increased stretch characteristics

ABSTRACT

A sock having a toe section, mid-section, and ankle section, wherein the denier of the toe and ankle sections is significantly less than the denier of the mid-section to provide increased stretch in the mid-section of the sock. To further increase the stretch in the mid-section of the sock, the mid-section is knitted with a longer stitch loop than the toe and ankle sections. A hosiery garment includes a leg section and a control top section. The control top section includes a stretch band that provides increased vertical stretch in that area. The stretch band is knitted in a jersey knit pattern with four courses of spandex yarn, where as the remainder of the control top section and leg sections are knitted with alternating courses of spandex and textured yarns.

This application claims the benefit of U.S. Provisional Application No. 61/592,765, filed Jan. 31, 2012, the disclosure of which is expressly incorporated herein by reference.

The present invention is directed towards hosiery garments and, more particularly, towards hosiery garments having increased stretch characteristics, thereby enabling such garments to fit a wider range of body sizes than prior art garments.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will be further apparent from the following detailed description of the preferred embodiments of the invention, when taken together with the accompanying specification and the drawings, in which:

FIG. 1 is schematic representation of a prior art sock;

FIG. 2 is a schematic representation of a sock made in accordance with a first embodiment of the present invention;

FIG. 3 is schematic representation of a prior art pantyhose garment; and

FIG. 4 is a schematic representation of a pantyhose garment made in accordance with a second embodiment of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The accompanying drawings and the description which follows set forth this invention in its preferred embodiments. However, it is contemplated that persons generally familiar with knitting hosiery garments will be able to apply the novel characteristics of the structures illustrated and described herein in other contexts by modification of certain details. Accordingly, the drawings and description are not to be taken as restrictive on the scope of this invention, but are to be understood as broad and general teachings.

In a first embodiment, the hosiery garment of the present invention is a sock having increased stretch characteristics in the foot portion in both the horizontal and vertical directions. As shown in FIG. 1, a typical sock 10 includes three sections, namely, an ankle section 12 that is configured to fit over the wearer's ankle, a toe section 14 that is configured to fit over the wearer's toes, and a mid-section 16 that is configured to fit over the middle of the wearer's foot. In a typical prior art men's size sock, the ankle section 12, mid-section 16, and toe section 14 are all knitted on a knitting machine with an 8″ cross stretch in each such section. A typical yarn used in such prior art sock is a nylon covered with spandex having a denier ranging from about 10 to about 20. The resulting prior art sock 10 has a horizontal stretch characteristic (direction of the length of the foot) in all three sections of the sock of about 225%, wherein about 1″ of the sock stretches to about 2¼″. This enables a typical men's size sock to fit the feet of men wearing a shoe size ranging from about size 10 to about size 13. The hosiery industry typically uses sock sizing standards established by the National Association of Hosiery Manufacturers (NAHM), which correspond with shoe sizes.

In order to increase the stretch characteristics of socks to accommodate larger ranges of foot sizes, the present invention, as shown in FIG. 2, is a sock 20 having an ankle section 22, toe section 24, and uniquely designed stretch panel 26 that extends between the ankle section 22 and toe section 24. Unlike the prior art sock 10 described above, the stretch panel 26 of the sock of the present invention is knitted with a different yarn than the ankle section 22 and toe section 24, and is knitted in a different way. Specifically, the yarn used in the stretch panel 26 of the sock 20 has a higher denier of spandex than the yarn used in the ankle section 22 and toe section 24. For example, the ankle section 22 and toe section 24 of sock 20 may be knitted with a yarn, such as nylon covered with a spandex, having a denier ranging from about 10 to about 20, as in the prior art sock 10. However, in the sock 20 of the present invention, the stretch panel 26 is knitted with a yarn, such as nylon covered with a spandex, having substantially increased denier, such as about 35 to about 45, and preferably about 44. Thus, the denier of the spandex used in the stretch panel 26 of the sock 20 is at least about 1.75 to 4.5 times greater than the denier of the spandex used in the ankle portion 22 and toe portion 24.

In addition to increasing the denier of the spandex in the stretch panel 26 of the sock 20, the knitting process is also modified for the stretch panel 26 as compared to the ankle section 22 and toe section 24. Specifically, when the sock 20 is being knitted, the knitting machine lengthens the loop of the stitch (creates a larger stitch) in the stretch panel 26 in order to loosen the cross stretch within that section 26 such that there is a differentiation in the stretch panel 26 of about 0.75″ to 1.5″, and preferably, about 1″. On a typical knitting machine, this is achieved by increasing the dropping distance of the cylinder that holds the knitting needles. Thus, unlike the prior art men's sock 10 having an 8″ cross stretch in all three sections of the sock 10, the sock 20 of the present invention may include, for example, an 8″ cross stretch in the ankle section 22 and toe section 24, but an increased 9″ cross stretch in the stretch panel 26. Similarly, a women's sock 20 constructed in accordance with the present invention, may include, for example, an 7.5″ cross stretch in the ankle section 22 and toe section 24, but an increased 8.5″ cross stretch in the stretch panel 26.

As a result of the increased denier of the spandex yarn and the lengthened loop of the stitch in the stretch panel 26 of the sock 20 (as compared to the ankle section 22 and toe section 24), the sock 20 of the present invention provides increased stretch characteristics in both the horizontal (direction of the length of the foot) and vertical (direction perpendicular to the length of the foot) directions, as compared to prior art socks 10 that are knitted with substantially the same denier of spandex throughout the foot of the sock and with the same loop length throughout the foot of the sock. As noted above, the prior art sock 10 has a horizontal stretch characteristic in all three sections of the sock 10 of about 225%, wherein about 1″ of the sock stretches to about 2¼″. However, in the sock 20 of the present invention, including the modifications to the spandex denier and loop length in the stretch panel 26 as described herein, about 1″ of the fabric in the stretch panel 26 stretches to about 3″ (about 300%) in both the horizontal and vertical directions. Therefore, the sock 20 has increased stretch characteristics that enable a typical men's size sock, for example, to accommodate the feet of men wearing shoe sizes ranging from about size 10 to about size 15, unlike the prior art sock 10 that accommodates shoe sizes ranging from about size 10 to only about size 13. Similarly, the sock 20 enables a typical women's size sock, for example, to accommodate the feet of women wearing shoe sizes ranging from about size 9 to about size 12, unlike the prior art sock 10 that accommodates women's shoe sizes ranging from about size 9 to only about size 11. Thus, the present invention provides increased stretch characteristics that enable a typically sized adult sock to accommodate at least one to two additional shoe sizes than prior art socks of the same size.

It should be understood that the sock of the present invention is not limited to an over the calf sock as shown in FIG. 2. Rather, the sock 20 of the present invention may be configured in different styles including knee high, crew, cuff, anklet, quarter, low cut, and footie socks, and still fall within the spirit and scope of the present invention.

Turning now to a second embodiment of the present invention, a hosiery garment, such as pantyhose, tights, leggings, stockings, knee-highs, and the like, is provided that includes increased vertical stretch characteristics in isolated and targeted portion(s) of the garment so the garment is able to accommodate a wider range of body sizes.

As shown in FIG. 3, a prior art control top pantyhose garment 30 includes a control top section 32 and a leg section 34, wherein the control top section 32 provides a reinforced panty. The control top section 32 is typically knitted in a jersey knit pattern with alternate courses of spandex and textured yarns, wherein the spandex yarn has a denier of about 70, which is heavier and stronger than the denier used in the leg section 34. The control top section 32 is designed to provide the wearer with stability and durability. However, one disadvantage of these prior art control top sections 32 is that they have a limited range of vertical stretch. For example, a typical stretch ratio for a prior art control top section 32 is about 1:3¾, meaning that about 1″ of fabric will vertically stretch to about 3¾″. This limited vertical stretch is apparent when women of different heights wear the same size pantyhose garment. Specifically, size charts for pantyhose garments are typically based on a combination of height and weight, however, such sizing ranges are not precise. Thus, a woman who is 5′3″ may wear the same size pantyhose garment as a woman who is 5′6″ according to a standard pantyhose size chart. However, the woman who is 5′6″, given her taller stature, may be more inclined to have issues with the control top section 32 slipping down when the woman bends over such that the woman feels the need to have to readjust the control top section 32 and pull up the top of the leg sections 34 when she stands back up, all due to there not being sufficient stretch in the vertical direction of the control top section 32.

The present invention, shown in FIG. 4 as part of a pantyhose garment 40, for example, includes a control top section 42 having stretch bands 46, 48, which are isolated and targeted areas of the control top section 42 that include increased vertical stretch characteristics. In the example shown in FIG. 4, the stretch band 46, which is proximate the top of the control top section 42, and the stretch band 48, which is proximate the bottom of the control top section 42 in the panty area, are both knitted in the same jersey knit pattern as the rest of the control top 42 but the bands 46, 48 are knit with four courses of spandex yarns instead of alternating courses of spandex and textured yarns. In one aspect of this embodiment, the denier remains the same in the stretch bands 46, 48 and in the rest of the control top section 42. However, by knitting the stretch bands 46, 48 with the four courses of spandex, as opposed to the alternating courses of spandex and textured yarn, the resulting garment 40 includes significantly enhanced vertical stretch characteristics in the stretch band 46, 48 areas. Specifically, about 1″ of fabric in the stretch band areas 46, 48 stretches to about 5″, as opposed to non-stretch band section of the control top 42 wherein about 1″ of the fabric stretches to about 3¾″.

By strategically positioning the stretch band 46 proximate the top of the control top section 42, and the stretch band 48 proximate the bottom of the control top section 42 near the leg portion 44, the wearer is optimally provided with the stability of the overall control top section 42 and the increased vertical stretch characteristics in the locations (stretch bands 46, 48) where it is most needed to accommodate comfort of the wearer during movement. This is particularly helpful for women whose height is at the top of their respective size ranges for the pantyhose garment so that they do not feel the need to constantly pull up the top of the control top section 42 and/or pull up the top of the leg portion 44. For women wearing the same size pantyhose garment who are on the shorter end of the respective size range, the stretch band areas do not necessarily need to increase to their maximum vertical stretch capacity so the fabric in those areas merely lies without buckling. Thus, the resulting pantyhose garment 40, as shown in FIG. 4 and described above, enables one garment size to accommodate a wider range of body shapes, and particularly a wider range of wearer heights.

It is noted that use of the stretch bands knitted with four courses of spandex yarns as opposed to alternating courses of spandex and textured yarns can be incorporated into other types of hosiery garments to also provide such other garments with increased vertical stretch in targeted and insolated areas. For example, in pantyhose that are sheer to the waist and do not have a control top section, a stretch band can be positioned under the waistband at the top of the panty. In knee-highs, thigh-highs, and stockings, a stretch band can be positioned under the welt/band. All such hosiery garments generally knitted with alternating courses of spandex and textured yarns but with an isolated area(s) knitted with four courses of spandex yarns fall within the spirit and scope of the present invention.

In both embodiments of the present invention as described herein, the increased stretch characteristics in the respective hosiery garments enable each such garment to fit a wider range of wearer body types. This provides the manufacturer with the flexibility to manufacture fewer sizes of such garments (resulting in less SKUs) while still accommodating the same or an even broader range of body configurations. This can result in significantly decreased manufacturing and marketing costs, which can also trickle down to decreased retail prices.

While preferred embodiments of the invention have been described using specific terms, such description is for present illustrative purposes only, and it is to be understood that changes and variations to such embodiments, including but not limited to the substitution of equivalent features or parts, and the reversal of various features thereof, may be practiced by those of ordinary skill in the art without departing from the spirit or scope of the present disclosure. 

What is claimed is:
 1. A sock comprising: a toe section knitted with a first yarn having a first denier; an ankle section knitted with the first yarn having the first denier; and a mid-section that is disposed between the toe section and the ankle section, the mid-section being knitted with a second yarn having a second denier, the second denier being about 1.75 to about 4.5 times greater than the first denier of the first yarn.
 2. The sock of claim 1 wherein the first yarn and the second yarn comprise nylon covered with spandex.
 3. The sock of claim 1 wherein the first denier of the first yarn is about 10 to about
 20. 4. The sock of claim 1 wherein the second denier of the second yarn is about 35 to about
 45. 5. The sock of claim 1 wherein the sock is knitted on a machine such that the toe section and ankle section are knitted with a first loop having a first length and the mid-section is knitted with a second loop having a second length that is about 0.75″ to about 1.5″ greater than the first length of the first loop.
 6. A hosiery garment comprising: a leg section; and a control top section further comprising a first stretch band; wherein, except for the first stretch band, the control top section is knitted in a jersey knit pattern with alternate courses of a first spandex yarn and a first textured yarn; and wherein the first stretch band is knitted in the jersey knit pattern with four courses of a second spandex yarn.
 7. The hosiery garment of claim 6 wherein the first spandex yarn is the same as the second spandex yarn.
 8. The hosiery garment of claim 6 wherein the first stretch band is proximate to a top of the control top section.
 9. The hosiery garment of claim 6 further comprising a second stretch band that is knitted in the jersey knit pattern with four courses of the second spandex yarn, the second stretch band being proximate to a bottom of the control top section. 